How to install a Borg Warner Disk Brake Diff'
24th April 2005
<-- Index | Showing 1-24 of 30 pictures | Next -->
We thought we'd throw all our Rear disk setup pics into another section as a "How To Do" for all you Chrysler owners That want your old girl to stop when you need it too & fast!!!

My only advice is to buy either a XE/XF (wagon, Panel van or Ute All leaf diff's unlike the sedans) & go for the LSD for the few extra bucks!

Aslo buy a Ratio that suits your needs eg: we wen't for the 2.77 ('cause we had it laying around for one) But the high ratio suits our needs ie country running over long distances 700+ kms a day every few weeks!!

But if your in the Burb's then I'd stick with a factory ratio of 2.92-1 or lower most of the XF utes has 3.27-1 great take offs with ease but hgher rev's on the 100 zones etc.. So just work out your needs first before buying that bargain! If your buying a LSD might pay to get it checked out b4 you buy it & servied b4 it goes into you beast no point having a bolt go through the rear case because it was loose (been there done that & still made it home!)  smile 

Also XE/F rotors are about $20 ea cheaper than the XD's that we used but Ebay has some great sellers on there & we got the rear rotor (Genuine Aust made DBA new in box) & a set of Bendix pads for the rears for $105.00 delivered!

Not bad when Bursons wanted $97 for the rotor alone & Repco $119 trade price for both of em! So yeah do your homework & shop around for the best prices for replacement components!

We'll have pics & decriptions up tomorrow 25/04/05 for the Park brakes cables etc...
Cheers
Nev & Kevin
Our New diff a 2.77 BW LSD Ford ZJ Fairlane (also XD) Diff
Our New diff a 2.77 BW LSD Ford ZJ Fairlane (also XD) Diff
1676.jpg
The ford diff is 6mm wider at the springs & 17mm wider in the track than the (CM) Chrysler's
The ford diff is 6mm wider at the springs & 17mm wider in the track than the (CM) Chrysler's
1677.jpg
We gave it a quick tighten & checked for wear (of which there was None!!) Plus fresh oil etc..
We gave it a quick tighten & checked for wear (of which there was None!!) Plus fresh oil etc..
1678.jpg
Then we painted it in PPC POR-15 hamer tough gloss black!
Then we painted it in PPC POR-15 hamer tough gloss black!
1679.jpg
We started with a set of Ford 1.5 inch lowering block's (we had them laying around!)
We started with a set of Ford 1.5 inch lowering block's (we had them laying around!)
1765.JPG
find the middle then cut from 0 to 5 mm taper
find the middle then cut from 0 to 5 mm taper
1766.JPG
The 5mm taper is for the front to get the pinion drive angle Up as per Valiant & not the XD
The 5mm taper is for the front to get the pinion drive angle Up as per Valiant & not the XD
1767.JPG
Then Drill a 13mm (1/2
Then Drill a 13mm (1/2") hole, Drilled 3 mm off centre to match the diff to the Val Springs (this one in for the RHS)
1768.JPG
Then trial fit it Should just drop straight onto the springs!
Then trial fit it Should just drop straight onto the springs!
1769.JPG
The original U bolts most likely won't fit! So get some New ones instead!
The original U bolts most likely won't fit! So get some New ones instead!
1770.JPG

1771.JPG

1772.JPG
The plates are put in with the high side facing the front due to the diff angle difference & then grab a set of new “U” bolts & install!
The plates are put in with the high side facing the front due to the diff angle difference & then grab a set of new “U” bolts & install!
1773.JPG
5 mm incline clearly seen here
5 mm incline clearly seen here
1774.JPG
Trail fitment of calipers etc to check for space! All good! :) 4 wheel disks & 1/2
Trail fitment of calipers etc to check for space! All good! :) 4 wheel disks & 1/2" studs all way around (huge safety upgrade!)
1817.jpg

1818.jpg

1819.jpg
You'll have to get someone to modifiy the park brake levers
You'll have to get someone to modifiy the park brake levers
1820.jpg
Modified Val / ford hybrid park brake levers on left & XD one on the right!
Modified Val / ford hybrid park brake levers on left & XD one on the right!
1829.jpg
Fresh coat of black for the backing plates
Fresh coat of black for the backing plates
2606.jpg
VHT Real Orange!!
VHT Real Orange!!
2652.JPG
Bright huh?
Bright huh?
2653.JPG
Both front & rear Calipers we're rebuilt with New pistons, seal kits, hoses & New Pads all way around (VJ Calipers on front for better brakes again!)
Both front & rear Calipers we're rebuilt with New pistons, seal kits, hoses & New Pads all way around (VJ Calipers on front for better brakes again!)
2714.JPG

2729.JPG